increased safety and productivity butt fusing hdpe pipe jim craig, p.e. industry relations manager...

INCREASED SAFETY AND PRODUCTIVITY BUTT FUSING HDPE PIPE

Jim Craig, P.E.

Industry Relations Manager

McElroy Manufacturing, Inc.

DISCUSSION POINTS

• Existing HDPE pipe job site set-up

• Improved HDPE pipe job site set-up

• Advantages of improved systemProductivity advantages

Cost advantages

Safety considerations and advantages

• Conclusions

Existing HDPE Pipe Job Site Set-up

Improved HDPE Pipe Job Site Set-up

ADVANTAGES OF IMPROVED PIPE HANDLING SYSTEM

• Low cost and easy to set-up

• Reduces contamination and damage to pipe

• Improved productivity

• Reduces job cost by eliminating equipment and personnel on job

• Improves safety for the operator and the fusion equipment

Handling System Productivity Analysis

Existing Improved

4-8” IPS 24-48 40-70

10-16” IPS 12-24 20-34

18-20” IPS 10-16 18-20

Estimated Joints per 10 Hour Day

Cost Analysis

Comparison Project

100 joints of 12” IPS DR 11 pipe

Compare both systems on total cost to install the pipe and the time required.

Estimate (10) hour days

Cost AnalysisHandling Systems Existing Improved

100 Joints 5 days (20 J/D) 3.45 days (29 J/D)

Fusion Equipment Rental ($275 /day) $1,375 $1,100

Fusion Operator ($480 /day) $2,400 $1,920

Loading/Pulling Equipment ($325 /day) (2) $3,250 (5 days) (1) $1,300 (4 days)

Loading Equipment Operator ($480 /day) (2) $4,800 (5 days) (1) $1,920 (4 days)

Rack System Rental ($100 /day) $ 400 (4 days)

Total Cost $11,825 $6,640

Savings – Cost $5,185

Savings – Time 1.5 days

Safety AnalysisRisk Reduction

Existing Pipe Handling SystemPipe loaded on pipe supports-------------------- 101 timesImproved Pipe Handling SystemPipe loaded on pipe racks-------------------------- 4-5 times

Advantages• Reduces the risk of personal injury• Reduces the risk of equipment damage • Reduces personal injury from lifting pipe on

the job site.• With powered rollers, it greatly reduces the

effort required to load the pipe into the machine.

Testimonial

Bill Hanes of VARI-TECH 

“The PolyHorse eliminates a large piece of construction equipment and speeds the whole operation. To watch a single worker feed a fifty foot piece of DR 9 into a fusion machine by hand was a thing of beauty.”

Additional Advantages of Improved Handling System

Additional Advantages of Improved Handling System

Image shown with items for increased productivity

2 each: PolyHorse Kit

3 each: Stationary Rollers

2 each: McElroy Fusion Machines

2 each: McElroy Pipe Stands

Additional Advantages of Improved Handling System

Image shown with items for increased productivity

2 each: PolyHorse Kit

2 each: McElroy Fusion Machines

4 each: McElroy Pipe Stands

Additional Advantages of Improved Handling System

Conclusions

• Job site set-up is the key to improved productivity and safety.

• The improved HDPE pipe handling system not only increases productivity but does it while decreasing project costs.

• This system is safer and keeps the pipe cleaner with less chance for damage.

• It also gets projects completed in less time and more efficiently.